Professional Documents
Culture Documents
(Mechanical Engineering Department, Maharana Pratap College of Technology, Gwalior /RGPV, Bhopal,
India)
2
(Mechanical Engineering Department, College of Science & Engineering Jhansi (UP), /AKTU, Lucknow,
India)
Abstract: This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting,
parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on
controlling the casting defects in foundry shop which comes in various check valves -PN 10 and these causes
may results the reduction of quality of casting. Here we have studied minimize the casting defects using
Taguchis method through change in various parameters like as pouring temperature, green strength, mould
hardness and permeability. These experiments were conducted based on standard acceptable and foundry men
experience in this casting organization for casting check valves -PN 10 of various sizes & types Significant
changes are taken during controlling the parameters. First we collected the data as casting defects from AV
VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task
we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are
four parameters responsible for these casting defects. 1. Pouring Temperature (oC) 2. Sand Particle Size (AFS)
3.Mould Hardness Number 4. Permeability Number
First we define the range of these parameters and then we perform the casting process at different trial and find
that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchis method and use of
MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting
process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in
casting defects.
Keywords: Foundry Shop, Casting Defects, Taguchis Method, Sand Casting, Check Valve PN 10
I.
Introduction
Foundry suffers from weak quality and productivity due to a huge number of process parameters, lower
automation and shortage of skilled workers. Defect free products are demanded in market but foundry finds to
meet the requirements [01]. In foundry we analyze the defects by non destructive methods and apply its
remedies carefully otherwise new defects occur. This is not an easy task. For example, when a gas porosity
defect occurs at high pouring temperature and when we decrease the pouring temperature, it may occur cold
shut defects. So casting is a very complex process. The success of a casting process depends greatly on the
properties of the molding sand. These include (i) Strength, (ii) Permeability, (iii) Deformation, (iv) Flowability,
and (v) Refractoriness [02].
II.
Literature Review
To reduce the rejection rate of castings, a detailed literature review was carried out for identifying related to
rejection control of castings in foundry using different simulation models and also some research papers which
gives solutions to solve the major defects during gating and feeding process in castings.
Udhaya Chandran.R.M[6] In this paper mainly focused to minimize the casting Defects such as, sand drop,
sand blow holes, scabs, pinholes. In that by using Taguchi method is a powerful problem solving for improving
quality of the product. The parameters considered are moisture content (%), Green Strength (g/cm 2), mould
hardness, sand practical size. The Taguchi approach is used to capture the effect of signal to noise ratio of the
experiments Based on the orthogonal array used due to optimum conditions are found. The outcome of this
paper that the selected process parameters continuously affect the casting defects in foundry. The improvement
expected in reduction of casting defects is found to be 47.66%.
S. V. Sapakal & M. T. Telsang et al. [20] Taguchi optimization method was applied to find the optimal
process parameters for penetration. A Taguchi orthogonal array, the signal-to-noise (S/N) ratio and analysis of
variance were used for the optimization of welding parameters. A conformation experiment was also conducted
and verified the effectiveness of the Taguchi optimization method. The improvement of S/N ratio is 2.13. The
experiment value that is observed from optimal welding parameters, the penetration is 5.25mm. & S/N ratio is
14.40.
www.ijesi.org
6 | Page
III. Methodology
Experiments were performed in foundry producing cast iron components. The study begins with the
manufacturing component check valves PN 10 in foundry where cold shut, scab, shrinkage are most important
defects observed, and due to these casting defects in casting the component having highest rejection rate is
identified using quality tools such as total rejection sheet, defective factor level sheet, table of defects and causes
with diagram. A model is also created for optimization of castings process through simulation and the major
causes are predicted and its solutions are given by defect diagnostic approach.
www.ijesi.org
7 | Page
Cold shut
5
7
8
Shrinkage
6
3
2
Others
2
3
4
% Rejection
5.25%
5.50%
6.25%
We see that many defects occur like cold shut, scab and shrinkage. We find out the causes of these defects like
pouring temperature, permeability, mould hardness and sand particles etc
3.4 Design of experiments for casting defects analysis
Process parameters of casting that influences the identified defects of check valves PN 10 with their levels are
shown in table-2.
Table 2. List of various parameters on basis of different levels
Parameter
Pouring Temperature (oC)
Permeability(No)
Sand Particle size(AFS)
Mould Hardness (Nu)
Range
1300 1350
130 180
50-55
50-80
Level A
1300
130
50
50
Level B
1320
150
52
60
Level C
1350
180
54
75
D
Mould Hardness Number
50
60
75
75
50
60
60
75
50
The main aim of the study was to reduce the Casting defects for which the ideal value is zero, the analysis was
carried out by using MINITAB-17 statistical software in which the S/N ratio was computed by using the Smaller
the better quality characteristics [-10*log10 (Y2/n)]. In the Taguchi method, the signal to noise ratio (S/N) is
used as the data transformation method that consolidates the data for each control array row over the various
noise levels into one value which computes both the mean and the variation present in the data. The equations
for calculating the signals to noise ratios were based on the characteristics of the response variables being
evaluated; nominal the best, smaller the better and larger the better. In the present work smaller the best
characteristic is used as the main aim is to reduce rejection in frames. The percentage rejection of Check Valves
-PN 10 for each trial was evaluated and the report generated was obtained from MINITAB-17 statistical
software.
www.ijesi.org
8 | Page
% Defects in Experiment
1
2
3
6.50
5.30
6.90
5.50
3.80
5.30
7.34
5.60
7.56
3.50
4.20
4.01
6.32
4.90
7.14
7.43
6.67
6.00
7.12
5.00
5.75
3.33
7.32
4.50
3.50
5.60
1.53
Total
18.70
14.6
20.5
11.71
18.36
20.1
17.87
15.15
10.63
S/N RATIO
Average
-15.8898
-13.7506
-16.6884
-11.8213
-15.7350
-16.5215
-15.5049
-14.0658
-11.1501
6.23
4.87
6.83
3.90
6.12
6.70
5.96
5.05
3.61
www.ijesi.org
9 | Page
% Rejection
5.25
5.50
6.25
5.667
AFTER EXPERIMENT
Month
April 16
May 16
June 16
Average % rejection
% Rejection
5.00
4.25
4.00
4.416
V.
Conclusion
After implementation various experiments and Testing techniques it is concluded that the optimum value of
Pouring temperature is 1340, Permeability is 150(No) , Sand particle Size is 42 AFS and Mould Hardness
Number is 91.132 . So, it is helpful to provide minimum defects during the casting done on applying given
parameters.
References
[1].
[2].
[3].
[4].
[5].
[6].
[7].
[8].
[9].
[10].
[11].
[12].
[13].
[14].
[15].
[16].
[17].
[18].
[19].
[20].
[21].
[22].
A text book of Principles of foundry technology by P.L.JAIN, Tata McGra Hill publications 5th edition.
A text book of Manufacturing Science by Amitabha Ghosh, and Ashok Kumar Maillk, EWP publication 2 nd edition.
A text book of Material Science by Mubeen & Mubeen, Khanna publishers , 2nd Edition
A text book of INDUSTRIAL MANAGEMENTS by J.SANGAL,SHUBHAM PUBLICATION IST edition.
Udhaya Chandran.R.M OPTIMIZATION OF PROCESS PARAMETERS TO MINIMIZE THE CASTING DEFECTS
International Journal of Advances in Engineering Science and Technology.
Udhaya Chandran.R.M, OPTIMIZATION OF PROCESS PARAMETERS TO MINIMIZE THE CASTING DEFECTS,
IJAEST,105-111.
Sunil Chaudhari*, Hemant Thakkar**(March 2014), Review on Analysis of Foundry Defects for Quality Improvement of Sand
Casting, ijera,Vol. 4, Issue 3( Version 1), 615- 618.
Binu Bose V, K N Anilkumar, ( December 2013),Reducing rejection rate of castings using Simulation Model, IJIRSET,589-597.
W. M. Wan Muhamad1, M. M. Salleh2, J. Mohamad3, A. F. Azmi4, Crack Defect Reduction in Die Casting Proces of Aluminium
Alloy Motorcycle Crankcases,01-05
A.P.More*,Dr.R.N.Baxi,Dr.S.B.Jaju, Review of Casting Defect Analysis to Initiate the Improvement Process, IJETS, Vol 2(4)
2011,292-295.
Rajesh Rajkolhe1, J. G. Khan2,( March 2014), Defects, Causes and Their Remedies in Casting Process: A Review, International
Journal of Research in Advent Technology, Vol.2, No.3,375-383.
Kumaravadivel1*, U. Natarajan2 Empirical study on employee job satisfaction upon implementing six sigma DMAIC methodology
in Indian foundry A case study, International Journal of Engineering, Science and Technology, Vol. 3, No. 4, 2011, pp. 164-184
Lakshamanan Singaram, IMPROVING QUALITY OF SAND CASTING USING TAGUCHI METHOD AND ANN
ANALYSIS,International journal on Design and manufacturing technologies,pages 01-05,
V.V.Mane1, Amit Sata2 and M. Y. Khire3, New Approach to Casting Defects Classification and Analysis Supported by
Simulation,01-18
S. Palit Sagar,( 2008), MODERN ULTRASONIC TECHNIQUES FOR DEFECT DETECTION IN CAST MATERIALS,
CAFP,88-94
Dr. B. Ravi A Holistic Approach to Zero Defect Castings. Technical Paper for 59 th INDIAN FOUNDRY CONGRESS,
Chandigarh, February 2011.
Wisam M. Abu Jadayil*,a(Dec 2011), Studying the Effects of Varying the Pouring Rate on the Casting Defects Using
Nondestructive Testing Techniques, JJMIE, Volume 5, Pages 521 526.
Paul Aondona IHOM1, Johnson AGUNSOYE2, Emmanuel Eric ANBUA3, Joy OGBODO4,( 2011), Effects of Moisture Content
on the Foundry Properties of Yola Natural Sand, Leonardo Electronic Journal of Practices and Technologies, page. 85-96
Achamyeleh A. Kassie1, Samuel B. Assfaw2, (May. 2013), Minimization of Casting Defects, IOSR Journal of Engineering
(IOSRJEN), Vol. 3, PP 31-38
1Virender verma,2Amit sharma,3 Deepak juneja, (October-November, 2014), Utilization of six sigma(DMAIC) Approach for
Reducing Casting Defects, International Journal of Engineering Research and General Science, 1065-1075
Mahesh N Adke, 4 December 2014, Optimization of die-casting process parameters to identify optimized level for cycle time using
Taguchi method, (IJIET),365-375]
Rasik A Upadhye and Ishwar P Keswani, Optimization of sand casting process parameter using Taguchi method in foundry,
International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 7, September- 2012 ISSN: 2278-0181.
www.ijesi.org
10 | Page